Insulating strip for supporting a composite structure

ABSTRACT

An insulating strip is configured to support two profiles or frames in a spaced relationship. The insulating strip includes a body extending in a longitudinal direction and has at least first and second longitudinal edges. The longitudinal edges are configured to be connected with the respective frames or profiles in a shear-resistant manner. Openings penetrate through one or more walls of the body and one or more struts separate the openings from each other in the longitudinal direction of the body. The body further comprises at least one attachment structure configured to retain a covering profile configured to cover the openings. The covering profile may be integral with the insulating strip body or may be a separate part. A composite structural unit comprises two frames supported in a spaced relationship by such an insulating strip.

CROSS-REFERENCE

The present application claims priority to German utility modelapplication number 20 2007 004 935.8 filed Apr. 2, 2007, German utilitymodel application number 20 2007 009 106.0 filed Jun. 28, 2007 andGerman utility model application number 20 2007 016 649.4 filed Nov. 27,2007, all of which are incorporated herein by reference as if fully setforth herein.

TECHNICAL FIELD

The present invention relates to insulating or separating strips thatmay be utilized, e.g., to separate and position two profiles or framesof, e.g., a window, a door or a façade. In a preferred embodiment, theinsulating or separating strip may provide a shear-resistant connectionof the two profiles or frames, even when the respective profiles orframes are subjected to different temperature environments.

BACKGROUND

In recent years, the use of double pane or double profile structures hasbecome more common in order to substantially reduce heat transferthrough, e.g., window, doors, façades and other building structures.Typically, such structures include an outer metal profile or frame, aninner metal profile or frame and one or more insulating strips or strutsfor maintaining the inner and outer profiles or frames in a spacedrelationship. In addition, such insulating strips or struts are oftenmade of a material exhibiting low conductivity in order to substantiallyminimize heat transfer from a warm side to a cold side of the compositestructure.

However, as discussed in U.S. Pat. No. 6,035,600, in the event that oneof the metal frames is subjected to a significantly differenttemperature environment than the other, thermal expansion of the warmerframe results in a displacement force between the respective frames ofthe composite section. As a result, the composite structure may bend orflex due to relative longitudinal displacement of the respective frames.This is known in the art as a “bimetal effect”, although it is notnecessary for the frames to be comprised of different metals. Rather, itonly refers to the different thermal expansions of the metal framescaused, e.g., by the metal frames being at different temperatures.

Heat sources causing a unilateral temperature rise include, e.g.,temperature differences between a room interior and the outside air(e.g., in winter) or incident solar radiation upon the outer frame(e.g., in summer) that causes the temperature of the outer frame to risedue to absorption of solar energy. The resulting deformation of thecomposite structure causes an arching that may impair the function ofthe window, door or façade element. U.S. Pat. No. 6,035,600 proposes aninsulating rod for connecting frames that is purported to provide aslight resistance to such relative longitudinal displacement.

German Patent No. 199 56 415 C1 discloses another solution to thislongitudinal displacement problem. Two longitudinal edges of aninsulating profile are connected by a substantially U-shaped outerbridge. The two longitudinal edges are respectively fitted to the outerand inner metal frames of a window, door or façade element. Theinsulating profile is preferably made of a synthetic material, such aspolyamide, polyester or polypropylene, and has a Young's modulus ofgreater than 2,000 N/mm². The U-shaped bridge imparts a sheer-resistantconnection between the inner and outer frames and resists relativelongitudinal displacement in the event that the inner and outer frameare subjected to different temperature environments.

German Patent Publication No. 198 53 235 A1 discloses an alternatesolution to this problem. In certain embodiments thereof, the insulatingstrip has a ladder-like structure, wherein a plurality of rungs or barsextend between respective longitudinal edges adapted to be connected torespective inner and outer metal frames of a window, door or façade. Theopenings between the rungs may have a circular-shape, arectangular-shape, an oval-shape or a slot-shape. The insulating profilemay be co-extruded using two materials having different hardness, suchthat the inner rungs exhibit an increased elasticity as compared to thelongitudinal edges. This design purports to minimize or prevent bendingor deflection of the two sides of the composite profile due totemperature differences. In order to prevent the penetration of moistureand/or dust through the openings, this reference recommends covering theopenings with a film, a sealing tape or a dipping varnish.

An insulating strip having a metal insert embedded in plastic is alsoknown from DE 198 18 769. This insulating strip also has openings thatimpart a ladder-like structure to it. The openings may be square-shaped,rectangular-shaped or substantially triangular-shaped. The openings inthe metal insert are intended to reduce thermal conduction and the metalinsert serves to prevent a complete failure or collapse of theinsulating strip in the event of a fire.

SUMMARY

However, there remains in the art a need to provide improved insulatingstrips or struts, which may be utilized, e.g., in composite structures,such as composite profiles or frames. In certain representativeembodiments, such insulating strips or struts exhibit relatively highshear strength while still providing improved thermal isolation andreduced risk of contamination of the interior portion of the compositestructure.

In one aspect of the present teachings, an insulating strip may bedesigned, e.g., for a window unit, a door unit, a façade unit and/oranother type of architectural unit, or any other unit that is generallycomprised of two frames or profiles supported in a spaced relationshiprelative to each other.

The insulating strip preferably has a body portion extending in alongitudinal direction (Z) and includes at least two longitudinal edgesseparated by a distance (a) in a transverse direction (X). Thelongitudinal edges are preferably configured or constructed for ashear-resistant connection with profiled or shaped components of therespective frames or profiles, such as the above-noted architecturalunits.

The insulating strip preferably has openings that penetrate through oneor more walls of the body in a height-direction (Y) of the insulatingstrip. The openings are preferably separated from each other in thelongitudinal direction (Z) by struts, bars, strips, supports, etc. Thesestructures may, in certain embodiments, give the insulating strip anoverall ladder-shaped appearance in plan view. However, in otherembodiments, the openings in the insulating strip may be circular, oval,hexagonal, i.e. other than square or rectangular, without departing fromthe scope of the present teachings.

The insulating strip preferably includes a connecting element orstructure configured to attach a covering element or profile thereto.Such a covering element may serve to cover the openings in theinsulating strip, thereby preventing contamination from entering intothe interior space defined between the two frames or profiles of theassembled composite structural unit.

In a further preferred embodiment, the covering element or profile isintegrally formed with the insulating strip and includes a clip elementconfigured to detachably connect with a terminal portion of the coveringprofile or element. Such covering profiles or covering sheets preferablycover the intervening spaces or openings between the rungs, struts.

The covering profiles or covering sheets can, for example, be clippedon, adhered to, extruded on, laminated to, etc., the insulating stripbody. The covering profiles/sheets may be either integral with theinsulating strip body or a separate piece.

Such covering profiles may, on the one hand, serve to prevent moisturefrom penetrating into a space or gap between the frames of the assembledcomposite structural unit. In addition or in the alternative, thecovering profiles may also protect the inner core. The covering profilesor covering sheets can be attached to the frames before or after theassembly of the units. Decorative elements can also be attached thereto.

In a further aspect of the present teachings, one or more clip heads mayproject from at least one side of the insulating strip in theheight-direction (Y). In addition or in the alternative, one or moreclip retainers may also extend in the height-direction (Y), preferablyfrom an opposite side of the insulating strip. The clip retainer(s)preferably define(s) a recess configured to receive and retain the cliphead(s). These clip heads and clip retainers may preferably serve toclip-fit or snap-fit a covering element or profile onto the insulatingstrip, thereby securely covering the openings in the insulating strip.

In a further aspect of the present teachings, the covering profile maybe in situ extruded together with the insulating strip body and may beconfigured to be bent over the insulating strip so as to cover one sideof the openings. A portion of the covering profile is further preferablyconfigured to be clipped or otherwise connected to the insulating stripbody, thereby securing the covering profile in a position that coversthe openings in the insulating profile.

In a further aspect of the present teachings, the covering profile maybe separate from the insulating strip body and may optionally have awidth in the transverse direction that is less than the width of theinsulating strip body. In this case, the covering profile may includeclip heads and/or clip retainers that is/are complementary to the clipheads and/or clip retainers defined on the insulating strip, as wasindicated above. In addition or in the alternative, the covering profilemay include abutment lips extending in the longitudinal direction (Z),which abutment lips are configured to contact the insulating strip body.More preferably, the abutment lips are designed to contact theinsulating strip body so as to seal the openings in the insulating stripbody from the outside environment.

In a further aspect of the present teachings, a composite profile mayinclude first and second window, door or façade frames with at least oneinsulating strip or strut disposed therebetween for supporting the twoframes in a spaced relationship. More preferably, the frames areconnected by the insulating strip(s) in a shear-resistant manner, suchthat the frames remain connected and supported, even if one frame issubjected to a significantly temperature environment than the otherframe. The insulating strip is preferably constructed so that a warmerframe is permitted to expand and displace relative to a cooler frame,while avoiding an overall bending or deflection of the assembledcomposite structural unit. In another embodiment, the insulated strip ispreferably constructed in order to apply a spring or elastic force thatresists relative longitudinal displacement of the frames, in the eventthat frames are disposed in different temperature environments. In allembodiments, the insulating strips or struts are designed to minimize orprevent the so-called “bimetal effect”, such that the frames of theassembled composite structural unit do not bend, deflect, deviate, etc.when the frames are situated in different temperature environments.

The term “insulating strip” as utilized herein may be substituted orreplaced with a variety of other terms, such as insulating bar,isolating strip, isolating bar, separating support, separating bar,insulating strut, isolating strut, separating strut, etc. These variousterms may be employed interchangeably unless otherwise indicated.Generally speaking, such structures preferably include the properties ofproviding a supporting function between two frames, profiles orcomposite structures and also reduce or minimize heat transfer acrossthe structure when the frames, profiles, composite structures connectedthereby are situated in different temperature environments.

In more preferred embodiments, such structures are preferably adapted toresist longitudinal distortion when the respective frames, profiles orcomposite structures are subjected to differing temperatureenvironments. Thus, when at least one insulating strip according to thisaspect of the present teachings is utilized to join or connect, e.g.,two metal frames, thereby forming a composite profile, movement of theframes relative to each other in the longitudinal direction can belimited and/or prevented by the high shear-resistance strength of theinsulating strip(s). The sheer-resistance can be determined by suitablyselecting the characteristics, properties and dimensions of theinsulating strips, such as the width, thickness, length, number, etc. ofthe connecting struts or bridges within each insulating strip, as wellas by appropriate selection of the material(s) forming the insulatingstrip.

In an advantageous manufacturing method, the insulating strips are firstformed from a suitable material, e.g., by extrusion, as profiledcomponents having a constant cross section over the entire length.Thereafter, the rungs or struts or bridges of the insulating strip aremanufactured to form openings in the insulating strip by a subsequentprocessing such as machining (e.g. milling), cutting (such as e.g.,laser cutting, water jet cutting, etc.), punching, etc. The removedmaterial can be recycled.

Preferably, the components of the unit, e.g., window frames, doorframes, façade frames, etc., are firmly and undetachably or permanentlyconnected via the insulating strip(s).

In addition or in the alternative, the intervening spaces or openingbetween the rungs, struts, bars, etc. of the insulating strip mayoptionally be filled with a material that has a lower thermal conductioncoefficient than the material of the rungs and/or insulating strip.

In addition or in the alternative, the covering profile/element may beelectrically-conductive. In this case, the covering profile/element cantake on the color of the metal profiles, e.g., by employing a powdercoating step to paint the covering profile and/or the assembledcomposite structural unit. Staining of the insulating profile and/orcovering profile/element is also possible.

One advantage of such an embodiment is that k-values (thermalconductivity properties) of the insulating strips are not undulydiminished by the attachment of the covering sheets/coveringprofiles/fillings, in particular the covering profiles.

Further features and advantages will result from the description ofexemplary embodiments with the aid of the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a first embodiment of an insulating strip; FIG. 1 a shows aplan view, FIG. 1 b shows a cross-sectional view perpendicular to thelongitudinal direction along line B-B in FIG. 1 a, and FIG. 1 c) shows across-sectional view perpendicular to the longitudinal direction alongline C-C in FIG. 1 a.

FIGS. 2 a-2 c show a second embodiment of an insulating strip havingdifferent rung widths in views corresponding to FIG. 1.

FIG. 3 shows a cross-sectional view perpendicular to the longitudinaldirection of an insulating strip when being connected with an innerprofile component and an outer profile component by crimping.

FIG. 4 shows a third embodiment of an insulating strip havingmeander-shaped rungs in a ladder-like structure.

FIG. 5 shows a fourth embodiment of an insulating strip having an insitu extruded cover, which view corresponds to FIG. 1 c.

FIG. 6 shows a modification of the fourth embodiment of FIG. 5.

FIG. 7 shows a fifth embodiment of an insulating strip; FIG. 7 a shows across-sectional view perpendicular to the longitudinal direction of theinsulating body, FIG. 7 b shows a cross-sectional view perpendicular tothe longitudinal direction of a to-be-clipped-on covering profile, andFIG. 7 c shows the assembled state of two metal profiles with aninsulating strip and covering profile disposed therebetween, in across-sectional view perpendicular to the longitudinal direction.

FIGS. 8 a-8 c show a sixth embodiment of an insulating strip, whereinFIG. 8 a shows a plan view perpendicular to the longitudinal direction,FIG. 8 b shows a cross-sectional view perpendicular to the longitudinaldirection, FIG. 8 c show a modification of the sixth embodiment in across-sectional view perpendicular to the longitudinal direction.

FIG. 8 d shows a seventh embodiment in a plan view perpendicular to thelongitudinal direction.

FIG. 8 e shows an eighth embodiment in a plan view perpendicular to thelongitudinal direction.

FIG. 8 f shows a ninth embodiment in a plan view perpendicular to thelongitudinal direction.

FIG. 9 shows a tenth embodiment of an insulating strip, wherein FIG. 9 ashows a plan view perpendicular to the longitudinal direction and FIG. 9b shows a cross-sectional view perpendicular to the longitudinaldirection.

FIG. 10 shows an eleventh embodiment of an insulating strip, whereinFIG. 10 a shows a plan view perpendicular to the longitudinal direction,FIG. 10 b shows a cross-sectional view perpendicular to the longitudinaldirection, FIG. 10 c shows a modification of the cross-sectional shapeperpendicular to the longitudinal direction, FIG. 10 d shows across-sectional view without openings, FIG. 10 e shows the embodiment ofFIG. 10 b with filling material, and FIG. 10 f shows the embodiment ofFIG. 10 c with filling material.

FIGS. 11 a-11 f show modifications of the sixth to ninth embodiments inviews corresponding to FIG. 8.

FIG. 12 a shows a modification of the embodiments of FIGS. 10 a and 10c.

FIGS. 12 b and 12 c show modifications of the embodiments of FIGS. 8 and11, respectively.

FIG. 12 d shows a modification of the embodiment of FIG. 10.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the insulating strips shown in FIGS. 1 and 2, the rungs 23 of aladder-shaped insulating strip body 20 extend between the continuouslongitudinal edges 21, 22 transverse to the longitudinal direction Z.However, the rungs 23 can also extend in an inclined manner (e.g., up toabout 20°) relative to the transverse direction. The rungs 23 can alsohave a curved shape in certain embodiments. Preferably, but notnecessarily, all rungs 23 may have the same shape.

In the present disclosure, the rungs 23 may also be referred to asstruts, bars, supports, braces, stanchions, stays, etc., which terms areinterchangeable in the structures according to the present teachings. Ineffect, the present teachings are directed to any structure thatprovides support between two essentially-parallel-extending edges orrails 21, 22 with intervening spaces or openings 24 formed therebetween.

The longitudinal edges or borders 21, 22 are preferably configured orshaped to be fitted with respective profiled components 31, 32 (see FIG.3) of a composite profile for a shear-resistant connection in thelongitudinal direction z. Representative, but not limiting, examples ofthe profiled components 31, 32 include window, door or façade elementsor frames, or any other architectural units, which may comprise metal incertain embodiments. The profiled component may be a composite structurethat includes, e.g., a metal frame surrounding a glass insert. Inaddition or in the alternative, the profiled component may include awood frame and/or wood insert and/or a plastic frame and/or a plasticinsert, etc.

In the embodiments of FIGS. 1-3, the longitudinal edges or borders 21,22 are formed as crimped heads 25 or crimped projections for beingcrimped within grooves or retainers formed in the profile components 31,32. The grooves or retainers may be each formed, e.g., by a bendableprojection 33 and an opposing wall segment 34. Other types ofconnections, such as adhering, form-fitting, friction-fitting, etc., arealso possible and are within the scope of the present teachings.

In the plan views of FIGS. 1 a and 2 a, the rungs 23 have a width b inthe longitudinal direction z, which is selected in accordance with therequired transverse tensile strength and the required transversestiffness, as well as the material utilized to form the rungs 23 and theinsulating strip body 20. Representative, but not limiting, rung widthsb may fall within the range of 0.5 to 10 mm, preferably 1 mm to 5 mm,and more preferably 1 mm to 3 mm.

In a cross-sectional view perpendicular to the longitudinal directionshown in FIGS. 1 b and 2 b, the rungs 23 have a height (thickness) h inthe y-direction, which also may be selected in accordance with therequired transverse tensile strength and the required tensile stiffness,as well as the material utilized to form the rungs 23 and the insulatingstrip body 20. Representative, but not limiting, rung heights h may fallwithin the range of 0.5 to 10 mm, preferably 0.5 mm to 5 mm, and morepreferably 0.7 to 2 mm.

The rungs 23 are disposed in the longitudinal direction z, preferablybut not necessarily with constant intervals or spacings d therebetween.Representative, but not limiting, intervals or spacings d may fallwithin the range of 1 mm to 100 mm, preferably 1 mm to 50 nm, morepreferably 1 mm to 5 mm, and most preferably 1 mm to 3 mm. Naturally,other widths, thicknesses, lengths and intervals are also possible inaccordance with the specifications of the intended use of the insulatingstrip 10.

Test results were obtained based upon ladder-like insulating strips 10having rungs 23 that, in the plan view in the longitudinal direction ofthe insulating strip, have a width b of 1 mm for a first embodiment anda width b of 3 mm for a second embodiment and, in the longitudinaldirection of the insulating strip, each have constant intervals d of 3mm. In the plan view in the transverse direction to the longitudinaldirection of the insulating strip, the openings 24 had a length c ofabout 14 mm with an overall size or width a of the insulating strip 10in the x-direction of about 23 mm. These insulating strips exhibitedvalues for the transverse tensile strength (tension in the direction ofthe connection of the profile components connected by the insulatingstrip, i.e. the x direction in FIGS. 1 and 2), which were higher forboth rung widths than for comparable profiles according to DE 199 56 415C1. In addition, the sheer-resistance (relative displacement of theprofile components connected by the insulating strip in the longitudinaldirection z of the profile components, i.e. in the longitudinaldirection z in FIGS. 1 and 2) could be adjusted simply by setting therung width to values below or above the values for comparable profilesaccording to DE 199 56 415 C1. Consequently, the amount of thelongitudinal displaceability is easily tailorable for a very hightransverse tensile strength. These strips were designed to provide alimited longitudinal displaceability in order to reduce the problem ofthe “bimetal effect” discussed above in the Background section.

FIG. 4 shows a third embodiment of an insulating strip 10 withmeander-shaped rungs 23 of the ladder-like structure in a viewcorresponding to FIG. 1 a, wherein the same reference numerals representthe same structures as FIGS. 1-3. This embodiment is also capable ofminimizing relative longitudinal displacement between frames of awindow, door, façade, etc.

In the fourth embodiment of an insulating strip shown in FIG. 5, an insitu extruded cover or covering profile 40 is provided for covering theintervening spaces 24 between the rungs 23. The embodiment of FIG. 5 isshown in a view similar to FIGS. 1 c and 2 c and may be mounted betweenprofiled components 31, 32 by crimping the crimping heads 25 in themanner shown in FIG. 3.

The covering profile 40 of FIG. 5 is integrally formed, e.g., by in situextruding it with the insulating strip body 20. In the cross-sectionalview perpendicular to the longitudinal direction z shown in FIG. 5, thecovering profile 40 is extruded so as to extend from one side of therungs 23 as viewed in the x-direction. The free or terminal end (edge)of the covering profile 40 is clipped onto the other side of the rungs23 as viewed in the x-direction. The clip connection is formed such thatthe clipping takes place in the height-direction, i.e. the y-direction.

The structure of the connecting arrangement may be selected according tothe specifications for the intended use of the insulating strip. Forexample, in FIG. 5, a snap-fit connection is shown, wherein the coveringprofile 40 includes a clipping head that elastically-resiliently fitsinto a clipping retainer formed adjacent the crimping head 25. However,other types of snap-fit, form-fit, friction-fit connections arepossible, as well as other types of connections, such as adhesives,fasteners, etc. are within the scope of the present teachings. In theembodiment of FIG. 5, it only significant that the covering profile 40is integrally manufactured with the insulating strip body 20 and then isbent or folded over so as to cover the openings 24. The form or type ofthe connection for holding the covering profile 40 in the positioncovering/protecting the openings 24 is not particularly limited.

In an alternative embodiment shown in FIG. 6, the clip connection isformed differently, such that the clipping takes place inclined to theheight-direction (y-direction) and a traction force in the transversedirection (x-direction) holds the clip in engagement. In thisembodiment, the covering profile 40 is shown extending over a rung 23and the rung 23 may have a different thickness or height h₁ than thethickness or height h₂ of the covering profile 40.

In the fifth embodiment shown in FIG. 7 a, clip heads 28, e.g., maleclip components, may be provided on one or more rungs 23 of theinsulating strip body 20. As a representative, non-limiting example, theclip heads 28 may be disposed such that, in the height-direction y, oneclip head 28 is disposed on one side and two clip heads 28 are disposedon the other side of the body 20. The single clip head 28 may bedisposed centrally on the rung 23 in the transverse direction x, whilethe two other clip heads 28 on the other side may be disposed at anidentical distance from the center. However, various other arrangementsof the clip heads 28 may be utilized, as will be apparent from thefollowing teachings.

In FIG. 7 b, a cover or covering profile 40 may be provided, e.g., withthree clip retainers 48, e.g., female clip components. The two outerclip retainers 48 may be provided at the same distance as the two clipheads 28 located on one side of the insulating strip body 20. The thirdclip retainer 48 is disposed centrally between the outer clip retainers48.

As is readily apparent from FIGS. 7 a-7 c, a cover or covering profile(element) 40 can be clipped onto one or both sides of the insulatingstrip body 20 without the need for providing differently-configuredcovers 40. However, if desired, it is also within the present teachingsto provide two different covers 40, each having different numbers orarrangements of clip retainers 48. Naturally, it is also within thepresent teachings to provide the clip head(s) 28 on the cover 40 and theclip retainer(s) 48 on the insulating strip body 20. Moreover, althougha snap-fit connection is shown herein as an exemplary embodiment, otherforms of connections are possible, as were discussed above.

The insulating strip body 20 may have a substantially constant thicknessh₁ over its width a₁ in the transverse direction x. The width a₂ of thecover 40 in the transverse direction x may preferably be less than orequal to the width a₁ of the insulating strip body 20. In this preferredembodiment, the edges of the cover 40 may also include two abutment lips42 formed substantially in the transverse direction x and extendingsubstantially in the longitudinal direction Z. The clip retainers 48 maybe formed to have a recess of depth h₄ in the height-direction y, asmeasured from the base of the clip retainer 48 to the outermost tip ofthe clip retainer 48. The depth h₄ is preferably less than the height h₃of the clip heads 28. The lips 42 end in the height-direction y at thepeak or terminal end of the clip retainers 48 or somewhat higher, asshown e.g., in FIG. 7 c.

In addition, as shown in FIG. 7 c, the abutment lips 42 may extend fromthe body 41 of the cover 40 at an angle, e.g., of between 90-135°, morepreferably between 100-120°. The ends of the abutment lips 42 maypreferably contact and form a seal between the cover 40 and theinsulating strip body 20 when connected thereto.

Although the cover 40 is preferably detachably coupled to the insulatingstrip body 20, it may also be permanently or fixedly connected to theinsulating strip body 20 in certain embodiments of the presentteachings. It is simply preferable that the cover 40 serves to coverand/or seal the openings 24 from the outside environment, so thatmoisture and/or dirt do not penetrate into the interior cavity of thefully-assembled composite structure, e.g., a double-pane window unit,door unit, etc.

Preferably, synthetic material having a Young's modulus value greaterthan 2000 N/mm² is used to form the insulating strip 10. Suitablesynthetic materials include, but are not limited to, polyamides,polyesters or polypropylenes, e.g., PA66 (Polyamide 66). The coveringprofile 40 may optionally be formed from a different material than theinsulating strip body 20.

The thickness h₁ of the insulating strip bodies 20 of all embodimentsmay optionally fall within the range of 1 mm to 50 mm, preferably 1 mmto 10 mm, more preferably 1 mm to 2 mm, even more preferably 1.4 to 1.8mm, although other thicknesses may be appropriate for certainembodiments of the present teachings. The thickness h₂ of the cover 40is preferably less than or equal to the thickness h₁ of the associatedinsulating strip body 20, although other thicknesses may be utilized, asdesired.

The embodiment shown in FIGS. 5 and 6 is well-suited for smaller valuesof the width a of the insulating strip body 20, e.g., in the range of 8to 20 mm, more preferably, 14 mm. In such embodiments, the thickness h₁preferably is, for example, in the range of 1-3 mm, more preferablyabout 1.4 mm.

The embodiment according to FIG. 7 is well-suited for values of thewidth a of the insulating strip body 20, e.g., in the range of 20 to 40mm, more preferably, 32 mm. In such embodiments, the preferred thicknessh₁ is in the range of 1.5 to 1.8 mm. PA66 is the preferred material forthe indicated widths and material thicknesses.

In one aspect of the present teachings, the insulating strip body 20 mayconsist only of synthetic material. That is, it may be formed without ametal insert. However, a metal insert also may be included in theinsulating strip body 20, if desired.

FIG. 8 a shows another embodiment of the present teachings, which isdesigned with an eye towards improved shear strength and is illustratedin a plan view perpendicular to the longitudinal direction. Theinsulating strip 10 may have a width a in the x-direction in the rangeof about 10 mm to about 100 mm. A plurality of openings 24 preferablypenetrate through the insulating strip body 20 in the height-direction(thickness-direction) y. In FIG. 8 a, the openings 24 have asubstantially triangular shape in the plan view and the corners of thetriangles are rounded so as to have a radius R. The triangles also havea height c in the transverse direction x.

The triangles may be arranged in an alternating manner, such that, inthe plan view in FIG. 8 a, a lateral side of one triangle is alternatelyarranged in parallel next to the left side, then to the right side, thenagain to the left side, etc. Consequently, the vertices of the trianglesare also arranged in an alternating manner. Rungs 23 are located betweenthe triangles and have a width b perpendicular to the sides of thebordering triangles. The triangles are separated from the respectiveouter longitudinal edges 21, 22 in the transverse direction x by adistance or length e. Thus, it follows that a=c+2e.

The insulating strip 10 has a constant height (thickness) h in theheight-direction y over its entire width, except for the crimping heads25, which may be thicker. Preferred values are provided as follows. Forinsulating strips 10 having a width a less than 22 mm, c preferablyfalls within the range of 7 to 10, more preferably about 8 mm. In suchembodiments, the radius R is preferably less than 2 nm, more preferablyless than 1 mm, and even more preferably about 0.5 mm. Such a radiusserves to avoid a concentration of stress or the formation of a type ofbending joint. The width b of the rungs 23 is preferably 1 to 3 mm, morepreferably 2 mm.

For insulating strips 10 having a width a greater than or equal to 22mm, c preferably falls within the range of 8 to 18 nm, more preferablyabout 12 mm. The height h in the height-direction y is preferably 1.2 to2.4 mm, more preferably about 1.8 mm. The strip 10 is preferably formedof PA66 GF25.

FIG. 8 c shows a modification of the sixth embodiment in across-sectional view, wherein the progression of the strip between thetwo crimping heads 25 is not linear, as in FIG. 8 b, but rather iscrooked or bent in the x-direction.

FIG. 8 d shows a seventh embodiment that differs from the sixthembodiment in that the openings 24 are not substantially triangular, butrather are substantially rectangular. The cross-section of theinsulating strip body 20 perpendicular to the longitudinal direction canbe the same as depicted as in FIG. 8 b or 8 c. The dimensions for a, b,c, e or R indicated above for the sixth embodiment also apply to theseventh embodiment. The dimension d, i.e., the extension or length ofthe openings 24 in the longitudinal direction z preferably falls withinthe range of 3 to 8 mm, more preferably about 5 mm. This dimension dalso applies to the preferred maximal extension or length of thetriangular openings 24 of the sixth embodiment, although the dimension dis not shown in FIG. 8 a.

FIG. 8 e shows an eighth embodiment that differs from the sixth andseventh embodiments, in that the openings are circular with a diameterC. FIG. 8 f shows a ninth embodiment that differs from the sixth andseventh embodiments, in that the openings are hexagonal. The remainingspecifications for the sixth and seventh embodiments also apply to theeighth and ninth embodiments, as far as they are applicable.

FIG. 9 shows an insulating strip having a so-called “package-design”,FIG. 9 a shows the plan view perpendicular to the longitudinal directionand FIG. 9 b show a cross-sectional view relative to the longitudinaldirection. This package-design is intended to be assembled in acomposite profile, such as is shown in an exemplary manner incross-section in FIG. 7 c.

In this embodiment, four crimping heads 25 are crimped in the fourcorresponding retainers or grooves of the profiled components (e.g.,metal frames), as is readily apparent from a comparison with FIG. 7. Toachieve this connection to the profiled components, the upper insulatingstrip portion 20 a shown in FIG. 9 b is crimped upwards (as comparedwith FIG. 7 c) and the lower insulating strip portion 20 b in FIG. 9 bis crimped downwards (as compared with FIG. 7 c). The two insulatingstrip portions 20 a, 20 b are connected by a clipped-on (snap-fit)connecting piece 20 c. This embodiment provides, on the one hand, ashielding against convection and radiation between the inner and outersides of the composite profile and, on the other hand, a plurality ofhollow chambers 20 d is formed. The hollow chambers 20 d are divided inthe height-direction y by a diagonal strut 20 e of the connecting piece20 c.

As can be seen in FIG. 9 a, the openings 24 have a width f in thetransverse direction x and a longitudinal extension or length d in thelongitudinal direction Z and can be formed in one or more insulatingstrip components 20 a, 20 b and/or in the connecting piece 20 c. Eachinsulating-strip component 20 a and 20 b shown in FIG. 9 b also hasoutwardly-directed protrusions 20 f that can form retainers, e.g., forrubber sealing elements and/or mounting components. However, theprotrusions 20 f are optional components of the illustrated embodiment.The number of openings 24 and the width and length of the openings 24are not limited to the arrangement shown in FIG. 9 a and may be freelyselected by the designer.

FIG. 10 shows another embodiment of the present teachings, which will bereferred to herein as a “hollow-chamber profile”. In such ahollow-chamber profile, hollow chambers are located in the transversedirection x between the crimping protrusions 25. For comparisonpurposes, the cross-section of a conventional hollow-chamber profile isshown in FIG. 10 d. As is readily apparent from a comparison with thecross-section of the eleventh embodiment in FIG. 10 b, the differenceis, in essence, that a wall is removed from the central hollow-chamberbetween the rungs 23, thereby forming an opening 24. The openings 24have a width g in the transverse direction x and a longitudinalextension or length d in the longitudinal direction z.

In particular for hollow-chamber profiles having a width a greater thanor equal to 25 mm, g preferably falls within the range of about 8 to 18mm, more preferably about 12 mm. With the modifications shown in FIG. 10c, an opening 24 is formed only on one side of the hollow-chambers. Inaccordance with the modifications shown in FIGS. 10 e and 10 f, the partof the hollow chamber profile, in which one or more openings 24 areformed, is filled with foam that serves as a filling material. This foampreferably is pure foam having a lower thermal conductance coefficientthan the material forming the insulating strip body 20. The otherspecifications noted above for, e.g., values a, b, d and R may belikewise utilized for this embodiment. The thicknesses h₅ and h₆ may bethe same or different.

FIGS. 11 a to 11 f show modifications of the sixth to ninth embodimentsin views with the same numbering a to f as FIG. 8, wherein a projection28 is formed on each insulating strip body 20. This projection 28protrudes from the insulating strip body 20 substantially in the heightdirection y and may preferably serve to obstruct convection andradiation. The height of the protrusion 28 in the height-direction y ischosen to achieve this effect. In FIG. 7 c, the installation of aninsulating strip 10 having such a protrusion 28 is indicated by brokenlines. An especially-effective obstruction of the convection andradiation is achieved when the above-described insulating strip 10 shownin FIG. 7 c) has one or more corresponding protrusions 28 that overlapwith the lower protrusion 28 as viewed in the transverse direction x.FIGS. 12 a-d show modifications of insulating strips having two suchprotrusions 28.

All embodiments shown in FIGS. 8 to 12 are preferably provided eitherwith an in situ extruded cover of the type shown in FIGS. 5 and 6 orwith clip-protrusions and/or clip retainers of the type shown in FIG. 7.In the alternative, it is also possible to provide sheets or films forcovering the openings or to introduce a foam into hollow-chambers of theinsulating strip body 20, which foam preferably comprises a materialthat is less heat conductive than the material of the insulating stripbodies.

Suitable materials for the insulating-strip bodies 20 are rigid-PVC, PA,PET, PPT, PA/PPE, ASA, PA66, wherein PA66 GF25 is preferred. Suitablefoams are preferably selected from thermosetting materials such aspolyurethane, and more preferably the foam has a relatively low density,such as about 0.01 to 0.3 kg/l.

Previous applications of ladder-like profiles were aimed at achievinglow shear strength (high longitudinal movability). In one otherapplication, openings were provided only to reduce the heat conductanceof a metal insert known to be extremely conductive.

With the preferred embodiments having one or more at least partly insitu extruded covers clipped onto one side of the insulating strip body,more preferably entirely clipped-on covers, as well as embodimentshaving adhered or laminated sheets for covering the openings, it hasbeen surprisingly found, in particular for the entirely or partlyclipped-on covers, that these covers only marginally influence thek-values, i.e. the heat-isolation characteristics of the insulatingstrip, as compared to non-covered versions.

Tests with a solid strip having a cross-section of the type shown inFIG. 5 b, i.e. with a strip having no openings, which strip has a widthof 25 mm and a height h of 1.8 mm and is made from PA26GF25, haveresulted in a k-value (W/m²K) of 2.4. An insulating strip of the typeshown in FIG. 8 d, in which c is 8 mm and d is 2 mm and without a cover,resulted in a k-value of 2.15 W/m²K. A corresponding strip with aclipped-on cover according to FIG. 7 had a k-value of 2.25 W/m²K. Thesemeasurements were performed in a so-called “hot-box”, wherein a systemhaving 25 mm wide, flat insulating strips was used as the initialsystem; the strips were not exchanged during the course of the test.Therefore, the improvements of the k-values are expected to be evenbetter in reality.

Although the cause of this effect has not yet been conclusivelyascertained, it is presumed that it lies in the form of the clipconnections, which severely restrict or narrow the heat transmissionpath through the cover.

For the embodiments having hollow chambers shown in FIGS. 9 and 10,which have already been tested in systems with very good insulatingproperties, these properties can be further improved. The use ofconvection- and/or radiation-shielding protrusions 28 also increases theeffect.

Each of the various features and teachings disclosed above may beutilized separately or in conjunction with other features and teachingsto provide improved insulating strips, and composite structuresincorporating such insulating strips, as well as methods for designing,manufacturing and using the same. Representative examples of the presentinvention, which examples utilize many of these additional features andteachings both separately and in combination, were described above indetail with reference to the attached drawings. This detaileddescription is merely intended to teach a person of skill in the artfurther details for practicing preferred aspects of the presentteachings and is not intended to limit the scope of the invention.Therefore, combinations of features and steps disclosed in the detaileddescription may not be necessary to practice the invention in thebroadest sense, and are instead taught merely to particularly describerepresentative examples of the present teachings.

Moreover, the various features of the representative examples and thedependent claims may be combined in ways that are not specifically andexplicitly enumerated in order to provide additional useful embodimentsof the present teachings. In addition, it is expressly noted that allfeatures disclosed in the description and/or the claims are intended tobe disclosed separately and independently from each other for thepurpose of original disclosure, as well as for the purpose ofrestricting the claimed subject matter independent of the compositionsof the features in the embodiments and/or the claims. It is alsoexpressly noted that all value ranges or indications of groups ofentities disclose every possible intermediate value or intermediateentity for the purpose of original disclosure, as well as for thepurpose of restricting the claimed subject matter.

The contents of U.S. Pat. Nos. 5,313,761, 5,675,944, 6,038,825,6,068,720 and 6,339,909 and US Patent Publication Nos. 2005-0100691 and2005-0183351 provide additional useful teachings that may be combinedwith the present teachings to achieve additional embodiments of thepresent teachings, and these patent publications are hereby incorporatedby reference as if fully set forth herein.

1. A composite structure comprising: a first frame, a second frame, andat least one insulating strip made of plastic and supporting the firstand second frame in a spaced relationship, the insulating stripcomprising: a body extending in a longitudinal direction and having atleast first and second longitudinal edges separated by a distance in atransverse direction, the first longitudinal edge being fixedlyconnected with the first frame by one of a crimped connection and arolled-in connection in a shear-resistant manner and the secondlongitudinal edge being fixedly connected with the second frame by oneof a crimped connection and a rolled-in connection in a shear-resistantmanner, wherein a plurality of openings penetrate through one or morewalls of the body in a height-direction thereof, the openings beingseparated from each other in the longitudinal direction of the body byone or more struts, the body further comprises at least one attachmentstructure configured to retain a covering profile, which is an integralpart of the insulating strip body, configured to cover the openings andto prevent moisture or dirt from penetrating into a gap defined betweenthe first and second frames, the covering profile is configured to befolded or bent over the insulating strip body so as to cover one side ofthe openings in the transverse direction and to detachably clip onto theinsulating strip body so as to secure the covering profile in theopening-covering position; the covering profile includes a clipping headthat elastically-resiliently fits into a clipping retainer formedadjacent the first longitudinal edge of the insulating strip body, thecovering profile being integrally connected to the insulating strip bodyadjacent the second longitudinal edge of the insulating strip body; theinsulating strip body has a width in the transverse direction of between8-100 mm and a thickness across the struts of one of (i) between 1-2 mmfor an insulating strip body width less than 22 mm and (ii) between1.2-2.4 mm for an insulating strip body width greater than or equal to22 mm and the insulating strip body comprises two or more struts havinga width in the longitudinal direction of between 1-3 mm and being spacedat constant intervals of between 1-5 mm.
 2. The composite structureaccording to claim 1, wherein the insulating strip body width in thetransverse direction is between about 8 mm to 20 mm.
 3. The compositestructure according to claim 2, wherein the struts are flexible andenable the first longitudinal edge to displace relative to the secondlongitudinal edge in the longitudinal direction when the first andsecond longitudinal edges are subjected to different temperatureconditions.
 4. A composite structure comprising: a first frame, a secondframe, and at least one insulating strip made of plastic and supportingthe first and second frame in a spaced relationship, the insulatingstrip comprising: a body extending in a longitudinal direction andhaving at least first and second longitudinal edges separated by adistance in a transverse direction, the first longitudinal edge beingfixedly connected with the first frame by one of a crimped connectionand a rolled-in connection in a shear-resistant manner and the secondlongitudinal edge being fixedly connected with the second frame by oneof a crimped connection and a rolled-in connection in a shear-resistantmanner, wherein at least three openings penetrate through one or morewalls of the body in a height-direction thereof, the openings beingrespectively separated from each other in the longitudinal direction ofthe body by at least two struts extending from the first longitudinaledge to the second longitudinal edge, a covering profile integrallyextends from the body and is configured to cover the openings so as toprevent moisture or dirt from penetrating through the openings into agap defined between the first frame and the second frame, the coveringprofile being disposed on a side of the insulating strip body that isopposite of the gap between the first and second frames, and at leastone attachment structure is integrally disposed on the body and isconfigured to retain a terminal end of the covering profile.
 5. Acomposite structure according to claim 4, wherein the at least oneattachment structure comprises a structure selected from a clip headprojecting from at least one side in the height-direction and a clipretainer having a recess extending in the height-direction.
 6. Acomposite structure according to claim 5, wherein the covering profileis configured to be folded or bent over the insulating strip body so asto cover one side of the openings in the transverse direction and todetachably clip onto the at least one attachment structure so as tosecure the covering profile in the opening-covering position.
 7. Acomposite structure according to claim 6, wherein the insulating stripcomprises polyamide and the first and second frames comprise a metallicmaterial.
 8. A composite structure according to claim 7, wherein thestruts have a width in the longitudinal direction of between about 0.5mm and 10 mm.
 9. A composite structure according to claim 8, wherein thestruts have a width in the longitudinal direction of between about 1 mmand 3 mm.
 10. A composite structure according to claim 8, wherein thestruts are spaced at constant intervals falling within a range of about1 mm to 5 mm.
 11. A composite structure according to claim 10, whereinthe struts are spaced at constant intervals falling within a range ofabout 1 mm to 3 mm.
 12. A composite structure according to claim 11,wherein the covering profile includes a clipping head thatelastically-resiliently fits into a clipping retainer formed adjacentthe first longitudinal edge of the insulating strip body, the coveringprofile being in situ extruded with the insulating strip body andextending from a position adjacent the second longitudinal edge of theinsulating strip body.
 13. The composite structure according to claim12, wherein the insulating strip body has a width in the transversedirection of between about 8 mm to 20 mm.
 14. The composite structureaccording to claim 13, wherein the struts are flexible and enable thefirst longitudinal edge to displace relative to the second longitudinaledge in the longitudinal direction when the first and secondlongitudinal edges are subjected to different temperature conditions.15. An insulating strip made of plastic and configured for supportingtwo profiles in a spaced relationship, comprising: a body extending in alongitudinal direction and having at least first and second longitudinaledges separated by a distance in a transverse direction, thelongitudinal edges being configured to be connected with the respectiveprofiles by one of crimping and rolling-in in a shear-resistant manner,wherein a plurality of openings penetrate through one or more walls ofthe body in a height-direction, the openings being separated from eachother in the longitudinal direction of the body by a plurality ofstruts, a covering profile integrally extending from the insulatingstrip body and being configured to cover the openings and at least oneattachment structure integrally formed on the insulating strip body andconfigured to retain the covering profile.
 16. The insulating stripaccording to claim 15, wherein the at least one attachment structurecomprises a structure selected from a clip head projecting from at leastone side in the height-direction and a clip retainer having a recessextending in the height-direction.
 17. The insulating strip according toclaim 16, wherein the covering profile is configured to be folded orbent over the insulating strip body so as to cover one side of theopenings in the transverse direction and to detachably clip onto the atleast one attachment structure so as to secure the covering profile inthe opening-covering position.
 18. The insulating strip according toclaim 17, wherein the struts have a width in the longitudinal directionof between about 1 mm and 3 mm and the openings have a width in thelongitudinal direction of between about 1 mm to 5 mm.
 19. The insulatingstrip according to claim 18, wherein the struts are flexible and enablethe first longitudinal edge to displace relative to the secondlongitudinal edge in the longitudinal direction when the first andsecond longitudinal edges are subjected to different temperatureconditions.
 20. The insulating strip according to claim 19, wherein thearrangement of the struts and the longitudinal edges gives the body ofthe insulating strip an overall ladder-shaped appearance in plan view.